Self-locking cushion assembly

ABSTRACT

A simplified, self-locking cushion assembly, such as a seat or back cushion for a vehicle seat. The cushion assembly incorporates a flexible cover having a flap portion along each of its edges. The flexible cover extends around a resilient cushion filler resting upon a cushion support which is attached to the frame member of the cushion assembly. In assembly, the flexible cover is pulled tightly over the top of the resilient cushion filler, thereby compressing the cushion filler between the flexible cover and the cushion support. A part of the flexible cover flap portion is tucked between the frame member and cushion support. The force created by the tendency of the compressed cushion filler to expand against the cushion support secures the flap portion in that position.

[ Apr. 2, 1974 SELF-LOCKING CUSHION ASSEMBLY [75] Inventors: Gordonl-lultquist, Chicago; Patrick ,1. Tyler, Oak Park, both of 111.

[73] Assignee: Coach and Car Equipment Corporation, Elk Grove Village,Ill.

[22] Filed: June 2, 1972 [21] Appl. No.: 259,244

[52] US. Cl 297/218, 5/353.l, 297/226 [51] Int. Cl. A47c 31/02 [58]Field of Search 297/218, 219, 225, 226,

[56] References Cited UNITED STATES PATENTS 2,612,941 10/1952 Naughton,Jr. 5/194 3,127,695 4/1964 Driscoll et al. 5/353.2

2,507,091 5/1950 Carlson 5/334 C 1,962,215 6/1934 Sallop 297/2263,596,989 8/1971 Van Ryn et a1 297/219 3,677,601 6/1972 Morrison et al.297/441 Primary Examiner- Bobby R. Gay

Assistant Examiner-Kenneth J. Dorner Attorney, Agent, or FirmMerriam,Marshall, Shapiro & Klose [5 7 ABSTRACT A simplified, self-lockingcushion assembly, such as a seat or back cushion for a vehicle seat. Thecushion assembly incorporates a flexible cover having a flap portionalong each of its edges. The flexible cover extends around a resilientcushion filler resting upon a cushion support which is attached to theframe member of the cushion assembly. In assembly, the flexible cover ispulled tightly over the top of the resilient cushion filler, therebycompressing the cushion filler between the flexible cover and thecushion support. A

part of the flexible cover flap portion is tucked between the framemember and cushion support. The force created by the tendency of thecompressed cushion filler to expand against the cushion support securesthe flap portion in that position. v

4 Claims, 3 Drawing Figures PATENTEBAPR 2 I974 FIG.2

FIG.|

SELF-LOCKING CUSHION ASSEMBLY BACKGROUND OF THE INVENTION The presentinvention relates generally to a simplified cushion assembly, such as aseat or back cushion for a vehicle seat, which is readily assembled anddisassembled thereby facilitating manufacture, maintenance and repair.

Cushion assemblies for vehicle seats conventionally comprise a rigidframe member over which is applied a support for a resilient cushionfiller, such as urethane foam or coil springs. A fabric cushion cover ismounted over the resilient cushion filler and its outer edges arepermanently secured to the rigid frame member by means of tacking orstapling or the like.

Because vehicle seats are subjected to a great deal of wear and abuse,they must be of sturdy construction. In particular, there must be asecure anchorage between the fabric cushion cover and the rigid framemember of the cushion assembly; and in conventional cushion assemblies,the fabric cushion cover is permanently secured to the rigid framemember.

In addition, conventional cushion assemblies are fairly complex in thatthey involve a number of skilled manufacturing operations in themounting and securing of the fabric cushion cover to the rigid framemember. This, in turn, has required a substantial amount ofmanufacturing time and has necessitated utilization of skilled labor forthe manufacturing process.

SUMMARY OF THE INVENTION The present invention utilizes the same basiccomponents now employed in conventional cushion assemblies and producesa sturdy cushion assembly, yet the assembly is relatively simple tomanufacture. In addition, unlike conventional cushion assemblies, thepresent invention provides for easy disassembly once mounted in thevehicle. This feature greatly reduces the vehicle down time and laborexpense associated with the cleaning and repair of conventional cushionassemblies.

The cushion assembly of the present invention incorporates a flexiblecushion cover, generally made of a fabric or plastic material, having aflap portion along each of its edges. In assembly, the flap portions aretucked between the frame member and cushion support in such a mannerthat the resilient cushion filler is compressed and the force created bythe tendency of the compressed cushion filler to expand against thecushion support secures the flap portions in that position.

Due to the fact that the flexible cushion cover is secured to the framemember by merely tucking its flap portions between the frame member andthe cushion support without the use of any tacks or staples which wouldpermanently secure it, the cushion cover may be readily removed andreplaced for cleaning and repair I once mounted in the vehicle by merelypulling out the tucked flap portions from between the frame member andcushion support. This assembly and disassembly procedure is simpleenough to be performed rapidly by unskilled labor.

Other features and advantages are inherent in the structure and methodclaimed and disclosed or will become apparent to those skilled in theart from the following detailed description in conjunction with theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a fragmentary, sectionalside elevational view of a cushion assembly constructed in accordancewith an embodiment of the present invention showing the cushion assemblyin an incompletely assembled condition;

FIG. 2 is a view similar to FIG. 1 illustrating the cushion assembly inan assembled condition; and

FIG. 3 is a fragmentary, perspective view of the'cushion assembly.

DESCRIPTION OF THE PREFERRED EMBODIMENT Referring to FIGS. 1-3, there isillustrated. an embodiment of a cushion assembly, indicated generally at50, constructed in accordance with the present inven- 4 tion. Cushionassembly 50 includes a peripheral frame member 10, generally constructedof metal, wood or some other rigid material, having a cushion support 12attached to it. As shown in FIG. 1, peripheral frame member 10 has a top32, a bottom 33, an inside margin 34 and an outside margin 35. Thecushion support is generally attached to frame member 10 by means ofstaples as shown at 14 in FIG. 3 or by tacks, glue or the like, and ismade of canvas, vinyl, flexible metal sheets or the like. Cushionsupport 12 is attached to frame member 10 in such a way that a pocket 15may be formed between the frame member 10 and cushion support 12.

Resting on cushion support 12 is a resilientcushion filler 16 aroundwhich is mounted a flexible cushion cover 18. Flexible cushion cover 18has flap portions 20 which extend beyond frame member 10 when flexiblecushion cover 18 is positioned over the top of cushion filler 16.Attached to the outer edge or terminal part 22 of flap portions 20 is arigid insert or element 24. Rigid insert 24 may be made of wood,plastic, steel or any other rigid material, and may be attached to outeredge part 22 by inserting it into a presewn tunnel 26 formed along outeredge part 22 of flap portions'20 or it may also be attached by stapling,gluing or the like.

In assembly, flexible cushion cover 18 is positioned over the top ofcushion filler 16 and each flap portion 20, having a rigid insert 24attached at its outer edge part 22, is extended beyond frame member 10as is shown in full lines in FIG. 1. The flexible cushion cover 18 isthen pulled tightly over the top of cushion filler 16, therebycompressing the cushion filler 16 between the cushion cover 18 andcushion support 12, and the flap portions 20 are folded around theunderside of frame member 10, as is illustrated in dashdot lines inFIG. 1. The outer edge part 22 of each flap portion 20, having rigidinsert 24 attached thereto, is then tucked into pocket 15 formed betweenframe member 10 and cushion support 12 as is illustrated in FIG. 2. Thetucking of the outer edge part 22 of flap portions 20 into pocket 15serves to maintain flexible cushion cover 18 in a tightly pulledposition over the top of cushion filler l6 and, therefore, maintains thecushion filler 16 in a compressed condition. A force, illustrated byarrow 30, is created bythe tendency of the resilient cushion filler 16to return to its expanded condition. This force 30 acts upon cushionsupport 12 thereby locking outer edge part 22 of flap portions 20securely between frame member and cushion support 12.

ln order to maintain a uniform appearance in the assembled flexiblecushion cover 18, opposite flaps, such as flaps 40 and 42 illustrated inFIG 3, are generally first tucked in place during assembly. The entireassembly operation may be performed without the use of tools. Likewise,by reversing the above-described assembly procedure and pulling outeredge part 22 of flap portions 20 from pocket 15, formed between framemember 10 and cushion support 12, top cover 18 may beeasilyand quicklyremoved from the cushion assembly without the use of tools. An upwardforce, generally applied by the workman s hand in the center of cushionsupport 12 against the resilient force of cushion filler 16, will aid inreleasing outer edge part 22 from pocket 15 in the disassemblyoperation.

Another advantage of the cushion assembly of this invention is that, asthe pressure against flexible cushion cover 18 is increased due to avehicle seat occupant resting against it, the downward force of thevehicle seat occupants weight upon flexible cushion cover 18 istransmitted through cushion filler l6 and against cushion support 12.This resulting force against cushion support 12 tends to lock outer edgepart 22 more securely in pocket 15.

The foregoing detailed description has been given for clearness ofunderstanding only, and no unnecessary limitations should be understoodtherefrom, as modifications will be obvious to those skilled in the art.

What is claimed is:

1. A cushion assembly comprising:

a peripheral frame member having a top, a bottom and outside and insidemargins;

a resilient cushion filler;

means for supporting said resilient cushion filler on said frame member;

flexible means for covering said resilient cushion filler;

said flexible'covering means having a flap portion;

said cushion supporting means being composed of flexible material;

the bottom of said cushion filler resting on said flexible cushionsupporting means;

means mounting said flap portion for movement between a tucked position,in which the terminal part of said flap portion is engaged between thetop of said frame member and said flexible cushion supporting means, andan untucked position, in which said terminal part of the flap portion isdisengaged from between said frame member and said flexible cushionsupporting means;

- said flap portion extending sequentially first along the outsidemargin of said frame member, then along the bottom of said frame member,then along the inside margin of said frame member and then terminatingbetween the top of the frame member and the bottom of said cushionfiller, when the flap portion is in said tucked position;

the terminal part of said flap portion lying in a plane substantiallyparallel to the bottom of said cushion filler when the flap portion isin its tucked position;

and means for detachably securing the terminal part of said flap portionbetween said frame member and said flexible cushion supporting meanswhen the flap portion is in its tucked position.

2. A cushion assembly comprising:

a peripheral frame member having a top, a bottom and outside and insidemargins;

a resilient cushion filler;

means for supporting said resilient cushion filler on said frame member;

flexible means for covering said resilient cushion filler; Y

said flexible covering means having a flap portion;

means mounting said flap portion for movement between a tucked position,in which the terminal part of said flap portion is engaged between thetop of said frame member and the bottom of said cushion filler, and anuntucked position, in which said terminal part of the flap portion isdisengaged from between said frame member and said cushion filler;

means for detachably securing the terminal part of said flap portionbetween said frame member and said cushion supporting means when theflap portion is in its tucked position;

means on said supporting means and on said flexible covering means forcompressing said resilient cushion filler into a compressed conditionwhen the flap portion is in its tucked position;

and means on said supporting means and on said frame member for securingthe terminal part of the flap portion in its tucked position when theresilient cushion filler is in its compressed condition.

3. A cushion assembly-as recited in claim 1 wherein:

said flexible covering means has a plurality of flap portions; and

said securing means comprises means for detachably securing the terminalpart of each of said flap portions between said frame member and saidcushion supporting means.

4. A cushion assembly as recited in claim 1 and further comprising arigid element attached to said terminal part of the flap portion.

1. A cushion assembly comprising: a peripheral frame member having atop, a bottom and outside and inside margins; a resilient cushionfiller; means for supporting said resilient cushion filler on said framemember; flexible means for covering said resilient cushion filler; saidflexible covering means having a flap portion; said cushion supportingmeans being composed of flexible material; the bottom of said cushionfiller resting on said flexible cushion supporting means; means mountingsaid flap portion for movement between a tucked position, in which theterminal part of said flap portion is engaged between the top of saidframe member and said flexible cushion supporting means, and an untuckedposition, in which said terminal part of the flap portion is disengagedfrom between said frame member and said flexible cushion supportingmeans; said flap portion extending sequentially first along the outsidemargin of said frame member, then along the bottom of said frame member,then along the inside margin of said frame member and then terminatingbetween the top of the frame member and the bottom of said cushionfiller, when the flap portion is in said tucked position; the terminalpart of said flap portion lying in a plane substantially parallel to thebottom of said cushion filler when the flap portion is in its tuckedposition; and means for detachably securing the terminal part of saidflap portion between said frame member and said flexible cushionsupporting means when the flap portion is in its tucked position.
 2. Acushion assembly comprising: a peripheral frame member having a top, abottom and outside and inside margins; a resilient cushion filler; meansfor supporting said resilient cushion filler on said frame member;flexible means for covering said resilient cushion filler; said flexiblecovering means having a flap portion; means mounting said flap portionfor movement between a tucked position, in which the terminal part ofsaid flap portion is engaged between the top of said frame member andthe bottom of said cushion filler, and an untucked position, in whichsaid terminal part of the flap portion is disengaged from between saidframe member and said cushion filler; said flap portion extendingsequentially first along the outside margin of said frame member, thenalong the bottom of said frame member, then along the inside margin ofsaid frame member and then terminating between the top of the framemember and the bottom of said Cushion filler, when the flap portion isin its tucked position; the terminal part of said flap portion lying ina plane substantially parallel to the bottom of said cushion filler whenthe flap portion is in its tucked position; means for detachablysecuring the terminal part of said flap portion between said framemember and said cushion supporting means when the flap portion is in itstucked position; means on said supporting means and on said flexiblecovering means for compressing said resilient cushion filler into acompressed condition when the flap portion is in its tucked position;and means on said supporting means and on said frame member for securingthe terminal part of the flap portion in its tucked position when theresilient cushion filler is in its compressed condition.
 3. A cushionassembly as recited in claim 1 wherein: said flexible covering means hasa plurality of flap portions; and said securing means comprises meansfor detachably securing the terminal part of each of said flap portionsbetween said frame member and said cushion supporting means.
 4. Acushion assembly as recited in claim 1 and further comprising a rigidelement attached to said terminal part of the flap portion.